Method of producing flatware



May 31, 1949. F. s. ROBINSON 2,471,900

METHOD OF PRODUCING FLATWARE Filed June 5, 1947 Y 2 sheets-sheet 1 FRIED 5. Roe//vso/V May 31, 1949. v F. s. ROBINSON 2,471,900

METHOD OF PRODUCING FLATWARE I Filed June 5, 1947 2 Shewets-Sheet 2 n," INVENTOR.

FRED 5. Ro/NLSo/v Patented May 31, `1949 METHOD OF PRODUCING FLATWARE Fred S. Robinson, Yalesville, Conn., assignor to E. Wallace & Sons Manufacturing Company, Wallingford, Conn., a corporation Application June 5, 1947, Serial No. 752,815

This invention relates to the manufacture of articles or" flatware such as spoons, forks, butter knives and spreaders, cake knives, etc.

In accordance with the usual prior practice in the manufacture of articles of iiatware such as those referred to, the articles are rst blanked from suitable metal by blanking dies which produce flat blanks. The fiat blank is then graderolled for providing a flat blank of graded thickness, more particularly, a blank which varies in thickness longitudinally thereof. Said graded blank is then cut to outline by cutting dies cor* responding in peripheral edge contour to that of the nished article. Thereafter, the handle part of the blank is shaped in an open die to the form it is to have in the finished article, and said die also impresses the surface ornamentation or design on the handle when the latter is to be provided therewith. After the handle-shaping or striking operation is performed, the other part of the blank, for example, the bowl-forming part thereof in the case of the spoon, is shaped or otherwise operated upon to form such part.

`The above described operation of shaping o-r striking the handle part of the blank in an open die has several disadvantages. Notably among the latter is the formation of a burr or flash along the side edges and outer end of the handle. This burr or flash must, of course, be trimmed off before the silver plating or other finishing operations are performed. Besides the labor and expense of the trimming operation and the subsequent sand-polishing operation required in order to remove the burr or flash and to smooth and polish the handle at its edges, the metal which is removed is largely Wasted, and, of course, this waste adds to the cost of production, especially when the articles are made of sterling silver. Moreover, when the handle is provided with surface ornamentation which, as stated, is struck up by the open die simultaneously with the shaping of the handle, such ornamentation or design which is provided on the surface of the handle at the edges thereof is frequently impaired either directly as a result of the formation of the burr or flash or indirectly as a result of the operations performed in trimming `off the burr or flash and polishing the side edge and end of the handle. Further, in performing the trimming operation which is usually performed by engaging the edges c-f the articles with a moving belt-carrying emery or other abrasive trimming medium, the operator usually holds a plurality of the articles in adjacent surface to surface relation while presenting the edges of the handles to the belt for the 4 Claims. (Cl. 76-105) trimming operation. As a result, the emery carried by the belt penetrates between the adjacent surfaces of adjacent handles of the articles and chafes or scars said surfaces. It Will be understood that this chaflng or scarring must be removed and that an additional operation is required for this purpose.

One of the objects of the present invention is i to obviate the above mentioned and other disadvantages which result from the above described handle-shaping operation. More particularly, in accordance with this object of the invention, the shaping of the handle is performed in such a manner as to obviate the production of a flash or burr on the edge and end of the handle, thus obviating the trimming and polishing operations required to remove the Hash or burr. Moreover, pursuant tothis object of the invention, the side edges and end of the handle are smoothly planished automatically during the handle-shaping operation. Furthermore, when ornamentation is provided on the handle during the handle-shaping operation, impairment of the ornamentation or design which frequently results by the trim ming and polishing operations is obviated.

Another object of the invention is to provide a handle-shaping operation which results in preserving in the nished handle al1 of the metal contained in the handle-forming part of the blank, so that the handle is thicker than the handle of an article made in accordance with the prior method of shaping the handle in an open die as described above.

A further object is to provide the article with a handle which is thicker along its edges than are handles which are shaped in an open die. More specically, in this connection, it may be noted that by reason of the thickening of the handle at the edges thereof and by conserving all of the metal of the handle-forming part of the blank in the handle of the finished article, a thinner blank may be used than was hereto fore possible Without decreasing the stiffness or rigidity of the handle.

A further object of the invention is the provision of a handle-shaping and ornamenting method which results in the provision of the handle with an ornamental design which is more sharply and distinctly brought up and defined Y 3 prove the construction and appearance of such articles.

The above and other objects, features and advantages of the invention and objects ancillary thereto will be fully understood from the following description considered in connection with the accompanying illustrative drawings.

In the drawings.'

Fig. 1 isf a side view of a die embodying the present invention and particularly well adapted for use in performing the method of this invention;

Fig. 2 is a sectional view on the line 2--2` of Fig. 1, showing the operation of the die', in ac"- cordance with the present invention, for shapingk the handle of the article;

Fig. 3 is a sectional View, on a larger scale, on the line 3-3 of Fig. 2;

Fig. 4 is a sectional view, on a greatly enlarged scale, on the line 4-4 of Fig. 2;

Fig. 5k is a perspective view showing the' companio-n parts of thev die and a fiat article blank, said parts of the die and said blank being separated from each other for the purpose of illus-v tration;

Fig. 6 is a side edge View of the blank after the handle-forming part thereof is shaped in accord-A ance with the presen-t invention;

Fig. 7 isa front view of the ii-nished article, shown as a spoon;

Fig. 8' isal view of the back of the finished I article;

Fig. 9 is an edge View of the finished article.

The present invention is hereinafter particularly described with reference to the manufacture of spoons asI the selected illustrative articles but it will be understood that the invention is similarly applicable to other articles of flatware such as forks, butter knives or spreaders, cake knives, etc. The articles are produced from flat blanks made of non-ferrous metal, for example, but Without limitation, nickel silver and sterling silver which are metals commonly employed for makin-g fiatware. These article blanks are customarily rolled in accordance with known practice to a graded thickness longitudinally of the 4blanks,` but the latter do not vary thickness along any line run-- ning laterally of the blank.

In -accordance with` the method of the present invention the nat grade -rolled article blank B shown in Fig. 5 is operated upon in a closed die of a power-operated diefpress for shaping the handle part of the blank to theY desired shape and for simultaneously impressing a surface design if the handle is to be provided therewith. More particularly, the handle part of the blank is pressed between the confronting surfaces of the upper and lower die-punches I0 and I2, respectively, while the handle is confined e'dgewise thereof by a rigid peripheral wall I-4 of the same peripheral contour as that of the peripheral edge of the handle part o-f the finished article. Said wall i4 defines an opening in the' stationary die plate I6. Said opening is of substantially the same size as the article blank. and corresponds in, shape to the peripheral edge contour thereof but said blank is preferably slightly smaller than said opening to provide'y clearance for the insertion of said blank in said opening preliminary to the operation of the diefpunches `Ifl) and i2 thereon.

`As shown in Fig. 2the confronti-ng or striking surfaces i8' and 20 of the dieeplmehes IU and I2,

respectively, are curved longitudinally' for im-V Parting: the desired, longitudinal. curvature to the handle-forming part of the blank in relation to the other part thereof which in the illustrative article, is the bowl-forming part of the blank. Further, when the handle of the spoon or other article of flatware is to be provided with surface ornamentation or designs said surfaces I8 and 20 of the die-punches are suitably formed as illustrated in Figs. 4 and 5 for impressing the surface designs in the handle-forming part of the article simultaneously with the shaping operation of said die-punches. As here shown, the front and back surfaces of the handle are struck by the die-'punches I2 and I0, respectively, but it will be understood that the punches may be reversed in respect to their operation on said surface of the handle-forming part of the blank. Also it will be noted that the die-punch, in this case the upper die-punch ID, which strikes the back of the handle is provided With longitudinally extending narrow recesses 22 (Figs. 4 and 5) in its surface I8- at the opposite side edges of the latter so as tov provide the marginal side edges of the handle with narrow ribs 24 which project beyond the back surface 26- of the handle, so that the side edges oi the handle are thickened, the outer surfaces of said ribs being continuous with the side edge surfaces' 28 of. the handle.

The operation of the' punches I0 and I2 on the handle-forming part of the blank within the opening defined by the peripherally continuous walll i4 of die plate IS produces a handle which is shaped as desired, in accordance with the relative longitudinal contours of the'confronti-ng surfaces I8 and 20 of the die-punclies I0 and t2, respectively, and at the same time the sideedges Qi and the' end edge 30 of the handle are smoothly planished since that part of they die plate open-y ing in which the punches I-0 and i2 operate is completely filled by the corresponding part of the die blank pursuant to' the striking vandl coihing operation thereon of the die punches in said. peripherally continuous opening of said die plate.

In the illustrated apparatus, the die punch I 0 is fixed to and carried by a holder 32 which is secured to the vertically movable member 3'4 of the die press. Said member 34 is guided for vertical movement by a plurality of vertical guide posts 36', one of which is shown in Fig. l. The depunc'h I2, is integral with or fixed to the base 38 which has a limited vertical guided movement in the recess 4U of a rigid, stationary block 42. The latter is rigidly secured to the bed 44 of the press in any suitable way as by a plurality of shoulder screws 46. A plurality of compression springs 48 and companion guide` pins 5i)y are associated with the base 38 of the die-punch |12 for moving the latter upwardly to move the shaped article to the top o-f `the opening in die plate I8y after the operation of the die-punches on said article, so that the shaped article may be conveniently removed. In this connection it will be noted that thev down-- ward movement of the die-punch i12' is limitedby the engagement of the iower end 52 of the base of said punch with the surface 54 of the sta tio-nary block 42, and that the upwardv movement of said die-punch II2 is limited by the engagement of lthe shoulder 56 of the base 38 ofy saiddie-punch with the lower surface 5'8 of die plate I6. It will be understood that in the operation of the ap'- paratus, the first part of the down stroke oi punch t0 clamps the blank against the punch I2 and then as' punch I0 continues to move it moves punch I 2 against the pressure of springs 48 to the izgid abutment provided by surface 54 of Trelockv The part ofthe punch `Ill which is movable in the opening of die plate I6 has a close sliding t at the opposite sides lil! and at its end 62 with the adjacent portions, respectively, of vertical wall id ofthe die plate IB. Similarly the lower die-punch i2 has a close sliding fit in the opening in die plate it, the opposite sides 64 and the end fit. of said die-punch being in sliding engagement with the adjacent portions, respectively, of vertical wall illof the die-plate. It will be understood, of course, that the vertical surfaces of the diepunches which are in sliding engagement with. the adjacent surface portionsyrespectively, of vertical wall it are parallel to said wall portions, respectively. By reason of this intertting sliding engagement of the die-punches with the wall lil of die plate it, the part of the blank which is struck by said punches is conned entirelyr to the space `between said punches laterally of the striking surfaces of said punches, so that no flash or` burr is `formed at the side edges of the handle. The upper edge ci wall I4 may be and preferably is slightly tapered or flared upwardly, as indicated at tt in Figs. 2, 4 and 5, for the purpose of facilitating the removal of the struck blank from die plate i5.

After the article blank is operated upon by the die punches as hereinbefore described for shaping the handle of the article and for ornamenting the surface of said handle, when such surface ornamentation is desired, the blank with the shaped handles is then subjected to the usual operations for forming the other part of the article. For example, in the case of the article herein selected for illustrative purposes as the spoon, the part lil of the blank is operated upon in the usual way to form the bowl 70a, of the spoon (Figs. 7 and 8). If the article is to be silver plated it may then be subjected to the usual silver plating process Without the intermediate trimming and sanding operations heretofore required in the manufacture of articles involving the use of an open die for shaping the handle. It will be noted that the design or ornamentation which is provided immediately at the edges of the handle, as indicated, for example, at 72 in Fig. 7 is preserved intact without impairment, since, in accordance with the present invention the shaping of the handle is accomplished without the production of a burr or ash. Moreover, it will be noted that all of the metal of the blank is preserved in the handle so that the latter instead of being thinner than the handle-forming part of the blank is thicker than the handle of a similar article which is operated upon in an open die in accordance with prior practice. Further it Will be observed that the handle is somewhat thicker at its side edges than a handle shaped in an open die from a blank of the same grade-rolled thickness, and that for this reason the articles produced in accordance with the present invention arenot only actually thicker than handles of articles shaped in an open die but have the appearance of being thicker and heavier than they actually are. In this connection it will be understood that this is of special advantage and value especially when the articles are made of sterling silver. In any event, however, and irrespective of whether the articles are made of sterling silver or of nickel silver or other appropriate non-ferrous metal, the preservation of all of the metal of the blank in the finished article, as Well as the thickening of the edges of the handle are highly advantageous and valuable since it is possible to use a thinner blank than was heretofore possible without decreasing the stiffness of .the handle in comparison with the stiffness oi handles formed inan open die in accordance with prior practice. It is also important to note that, in accordance with the present` invention, as hereinbefore described, the side edges of the handle are smoothly planished so that, as stated above, it is unnecessary to tri-m the handle at its side edges or even to polish the latter before the iinal overall polishing of the article. It will be understood, however, that it is within the scope of the present invention to provide the vertical wall it of the die plate IG with a series of parallel shallow vertical grooves in case it is desired to correspondingly shape the side edges of the handle.

It will be understood that various changes may be made in the die apparatus and in the mode of practicing the method of the present invention without departing from the underlying idea or principles thereof within the scope of the appended claims.

Having thus described my invention, what I claim and desire to secure by Letters Patent is:

1. In the manufacture of articles of atware such as spoons, forks, butter knives, and spreaders, cake knives, etc., from non-ferrous metal blanks, the method which comprises placing a peripherally shaped blank of variable thickness in a die opening closed at its peripheral side, with the edges of the handle-forming part of the blank lying close to and conned by the adjacent portions, respectively, of the side-closing wall of said opening, and striking said handle-forming part at the opposite sides thereof in said opening between diepunches operable on said part in said opening to shape said part to the desired form and to increase the thickness of the marginal side edges of the handle-forming part of the blank.

2. In the manufacture of articles of flatware such as spoons, forks, butter knives and spreaders, cake knives, etc., from non-ferrous metal blanks, the method which comprises placing a peripherally shaped grade-rolled blank in a dieopening closed at its peripheral side, with the edges of the handle-forming part of the blank lying close to and conned by the adjacent portions, respectively, of the side-closing wall of said opening, and striking said handle-forming part at the opposite sides thereof in said opening between handle-shaping die-punches which slidably engage said wall portions in intertting relation .therewith whereby the metal of said handle-forming part is conned entirely between said die-punches and said Wall portions of the die and the edges of the handle are planished by said wall portions, one of said punches having longitudinally extending recesses at the side edges of its striking surface whereby the marginal side edges of .the handle-forming part of the blank are thickened by said striking operation of said punches on said part of the blank.

3. In the manufacture of articles of atware such as spoons, forks, butter knives and spreaders, cake knives, etc., from non-ferrous metal blanks, the method `which comprises placing a peripherally shaped grade-rolled blank in a dieopenng closed at its peripheral side, with the edges of the handle-forming part of the blank lying close to and conned by the adacent portions, respectively, of the side-closing wall of said opening, and striking said handle-forming part at the opposite sides thereof in said opening between die-punches operable on said part in said opening to shape said part to the desired form mim FHBB rami Sto rsimlianeously iimpress a :surface tdesign therennsandfto increase the rahicknessef hesi'de edges f'o'f ithe ihandle-{f'orming `peint fof lthe 251mm,

74.1111 fthe manufacture :'of Aarticles of fiaware such zasfspoo'ns, Eforks, butber knives .and spread- :ers, zealfke zkn'ives, .et'c., :from :non-termas :metal blanks, the .zmeih'ed rwhich fcom'pn'is'es providing sa blank ef izthe fnis'hed peripheral :eentour and :off variable tiiJhi'ch'ness, :and thereafter pressing farrd @dining Sthe Yhandle `.part :Uf ihe lolank Lt'o the rie-- sired :sh-ape between the 4confronting surfaces of die-Lpimch'es disposed at Aopposite sid'es, iresiden tively, Jof said ihan'dle part with iihe Yhandle "rilos'e so and'sconned fe'dgewis'e whereof Sby :a nigi meripheral Wall of the same peripheral cmmmr asthat uf fthe =periphera1 .edge l:or the hemdle partei ihe article, Lone :of .said rpnnches :havingflmrgltudirrally .extending recesses fatithe sideieugesadf itsfstriking surface whereby fthe vside :edges :of 1th@ handlefamning part fufithe blank :are Tbhickenedikiyssad striking operation of said punches mnsaid fpa'nt of whe bla-rik.

FRED S. ,-LMBINSQ.

IB iCI-IED The fllowing `)references faire :of :record 'in v`the Tile xof this patent:

UNIEDED STQ'DES 'LPAEENSUS 

